Abstract
In an effort to reduce waste and manufacturing costs in automotive assembly tooling, this study evaluates the potential of replacing the traditional machining of technical plastic connector (CH) supports with Fused Deposition Modelling (FDM) using Polylactic Acid (PLA). Comprehensive experimental evaluations were conducted using different printing parameters to cover mechanical properties (tensile, flexural and compressive strength), environmental durability (thermal ageing, moderate heat exposure and chemical resistance) and functional performance (torque, drop and cyclic load). The results confirm that FDM-manufactured PLA components meet the operational requirements for low-volume automotive tooling. Specifically, a cubic infill density of 20% was found to provide the optimal balance of structural integrity, resource efficiency, and mechanical durability, offering a sustainable and cost-effective alternative to conventionally machined plastics.